Olefin oligomerization

ABSTRACT

This invention is to a method of oligomerizing an olefin feed stream. The olefin feed stream contains at least one C 2  to C 12  olefin to obtain an olefin feed stream and has less than 1,000 ppm by weight oxygenated hydrocarbon. The olefin is oligomerized by contacting with an acid based oligomerization catalyst.

[0001] This application claims priority to U.S. Provisional PatentApplication No. 60/265,700, filed Feb. 1, 2002.

FIELD OF THE INVENTION

[0002] This invention relates to a process for oligomerizing olefin. Inparticular, this invention relates to a process for oligomerizing anolefin stream containing a low concentration of oxygenated hydrocarboncontaminants.

BACKGROUND OF THE INVENTION

[0003] The oligomerization of olefin compounds is conventionallyaccomplished by catalytic reaction. Oligomerization catalysts aretypically nickel based catalysts or acid based catalysts. Generally,oligomerization processes which use nickel based catalysts are carriedout by forming a homogenous suspension of catalyst, olefin feed andproduct, whereas the acid based catalyst systems are carried out using aflow-through, fixed bed type of arrangement. The homogeneous suspensiontype of system is generally much more technically difficult to operate,but offers certain advantages in its ability to product a greater degreeof “semi-linear” oligomer products. These semi-linear products areproducts with limited branches, and can be beneficial in certain usessuch as further reaction to form plasticizers, solvents or diesel typefuels in which limited branching is desirable.

[0004] Cosyns, J. et al., in “Process for upgrading C₃, C₄ and C₅olefinic streams,” Pet. & Coal, Vol. 37, No. 4 (1995), describe a nickelbased catalyst system known as the Dimersol® process. This process isuseful for dimerizing or oligomerizing a variety of olefin feeds. Inparticular, the process is useful for dimerizing or oligomerizingpropylene, butylene and pentylene streams.

[0005] U.S. Pat. No. 6,143,942, to Verrelst et al., describes theoligomerization of C₂ to C₁₂ olefins using a mixture of ZSM-5 andZSM-22, and ZSM-57 and ZSM-22. The particular combination of catalystsproduces a high yield of trimer products.

[0006] U.S. Pat. No. 5,874,661, to Verrelst et al., describes a systemfor reducing branching of oligomerized olefins. In this system, lowerolefins, such as propene or butene, are oligomerized to an oligomer orhigher olefin using an acid based catalyst such as ZSM-5. The higherolefin is then isomerized also using an acid based catalyst, such asZSM-5 or ZSM-22, to isomerize the higher olefin and reduce the degree ofbranching. The isomerized higher olefin is then hydroformylated to formsurfactants and polyolefin stabilizers.

[0007] U.S. Pat. No. 5,762,800, to Mathys et al., describes a processfor oligomerizing C₂ to C₁₂ alkenes using a zeolite oligomerizationcatalyst. The catalytic life of the catalyst is increased by hydratingthe olefin feed to the oligomerization reactor.

[0008] U.S. Pat. No. 6,049,017, to Vora et al., describes thedimerization of a predominantly n-butylene containing feed stream. Then-butylene feed stream is ultimately derived from an olefin streamcontaining a variety of butylenes produced by a methanol to olefinsreaction unit. The butylene stream from the methanol to olefins unit ispretreated by a combination of partial hydrogenation of dienes andisobutylene removal by way of an MTBE process, before sending theresulting n-butylene stream to the dimerization unit.

[0009] Often, efficiency of the oligomerization process is reduced dueto the presence of greater than desirable quantities of inert componentsin the feed stream; for example, alkanes such as propane and butane.These inert components, in essence, take a free ride through thereaction system, taking up valuable reactor volume without being reactedto desirable products. Therefore, multiple separations processes toremove inert components are often required.

[0010] Olefin feed streams can also contain contaminants that act aspoisons to oligomerization catalysts. For example, nickel basedoligomerization catalysts are quite sensitive to sulfur and nitrogen.Such contaminants can have a particularly significant impact on theactive life of the catalyst, shortening the life of the catalyst to thepoint where the reaction process is not feasible to operate.

[0011] It is, therefore, desirable to provide olefin feed streams whichcan be oligomerized at high efficiency and run for an extended periodwithout causing early replacement or regeneration of catalyst. It wouldbe particularly desirable to take advantage of an olefin feed streamwhich needs little pretreatment for use in an oligomerization system.

SUMMARY OF THE INVENTION

[0012] This invention provides a method for oligomerizing an olefin feedwithout substantially adversely affecting catalyst life. The oligomerproduct can be obtained without having to treat the olefin feed toremove contaminants such as sulfur and nitrogen. The oligomer product isoptionally converted to a hydroformylated product with desirablebranching characteristics.

[0013] In one embodiment, the invention provides a method ofoligomerizing olefin which comprises removing oxygenated hydrocarbonfrom an olefin stream containing at least one C₂ to C₁₂ olefin to obtainan olefin feed stream comprising less than 1,000 ppm by weightoxygenated hydrocarbon. The olefin feed is contacted with an acid basedoligomerization catalyst to oligomerize the olefin in the olefin feed.

[0014] In another embodiment, the invention comprises contacting anoxygenate with a molecular sieve catalyst to form an olefin streamcontaining at least one C₂ to C₁₂ olefin. Oxygenated hydrocarbonsshowing up in the formed olefin stream are removed from the olefinstream to obtain an olefin feed stream comprising less than 1,000 ppm byweight oxygenated hydrocarbon. The olefin feed stream is then contactedwith an acid based oligomerization catalyst to form an olefin oligomer.

[0015] An alternative embodiment comprises contacting the oxygenate witha molecular sieve catalyst to form an olefin stream containing at leastone C₂ to C₁₂ olefin. The a C₃ to C₆ olefin stream is recovered from theolefin stream, and oxygenated hydrocarbon is removed from the olefinstream to obtain an olefin feed stream comprising less than 1,000 ppm byweight oxygenated hydrocarbon. The olefin feed stream is then contactedwith an acid based oligomerization catalyst to form an olefin oligomer.

[0016] In another embodiment of the invention an olefin feed stream isprovided which comprises at least one C₂ to C₁₂ olefin and oxygenatedhydrocarbon. Preferably, the oxygenated hydrocarbon is provided in theolefin stream at a concentration of greater than 5 ppm by weight andless than 1,000 ppm by weight. The provided olefin stream is thencontacted with a zeolite oligomerization catalyst to oligomerize theolefin in the olefin feed.

[0017] In yet another embodiment of the invention, the acid basedoligomerization catalyst is a zeolite oligomerization catalyst. Thezeolite oligomerization catalyst is desirably selected from the groupconsisting of TON, MTT, MFI, MEL, MTW, EUO, ZSM-57, ferrierites,offretites, ZSM-4, ZSM-18, Zeolite Beta, faujasites, zeolite L,mordenites, erionites and chabazites. Preferably, the zeoliteoligomerization catalyst is ZSM-22, ZSM-23 or ZSM-57, more preferablythe zeolite oligomerization catalyst is ZSM-22 or ZSM-23. The acid basedoligomerization catalyst can also be a solid phosphoric acid catalyst.

[0018] Surface activated zeolites such as mono-dimensional 10-ringzeolites, such as ZSM-22 or ZSM-23, are also useful as oligomerizationcatalysts. Such selectivated catalysts produce near linear oligomers.

[0019] It is desirable to have a reasonable quantity of olefin in theolefin feed stream for better efficiency. Preferably, the olefin feedcontains less than 50 wt % alkane; more preferably, the olefin feedcontains at least 50 wt % olefin.

[0020] In another embodiment of the invention, catalyst life isprolonged by hydrating the olefin feed prior to contacting with theoligomerization catalyst, particularly a zeolite oligomerizationcatalyst. Preferably, the hydrated olefin feed has a water content of0.05 to 2 weight percent.

BRIEF DESCRIPTION OF THE DRAWING

[0021] Examples of various embodiments of the invention are shown in theattached FIGURE which depicts data derived from the Examples.

DETAILED DESCRIPTION OF THE INVENTION

[0022] This invention provides a method of oligomerizing olefin bycontacting an olefin feed with an acid based oligomerization catalyst.Examples of an acid based oligomerization catalyst include solidphosphoric acid catalysts and zeolite oligomeriation catalysts.

[0023] The solid phosphoric acid catalysts used in this invention can beany conventional solid phosphoric acid catalyst that is active in olefinoligomerization reactions. Such catalysts comprise phosphoric acid on asilicon based support. Examples include phosphoric acid on silica gel,diatomaceous earth, and kieselguhr. More specific examples are found inU.S. Pat. Nos. 2,586,852; 2,713,560; and 4,675,463, the descriptions ofwhich are incorporated herein by reference.

[0024] The zeolite oligomerization catalysts can be any catalyst that isactive in olefin oligomerization reactions. Such catalysts include, forexample, zeolites of the TON structure type (for example, ZSM-22, ISI-1,Theta-1, Nu-10, KZ-2); zeolites of the MTT structure type (for example,ZSM-23, KZ-1); zeolites of the MFI structure type (for example, ZSM-5);zeolites of the MEL structure type (for example, ZSM-11); zeolites ofthe MTW structure type (for example, ZSM-12); zeolites with the EUOstructure type (for example, EU-1); zeolite ZSM-57, or any member of theferrierite structure family. Other examples of suitable catalysts areoffretites, ZSM-4, ZSM-18 or zeolite beta. Synthesis of these catalystsare described in Synthesis of High-Silica Aluminosilicate Zeolites by P.A. Jacobs and J. A. Martens (published as volume 33 in the seriesStudies in Surface Science and Catalysis), the disclosure of which isincorporated herein by reference.

[0025] Additionally, the catalyst used in this invention can be azeolite synthesized without addition of a template. Examples includefaujasites, zeolite L, mordenites, erionites and chabazites, thestructures of which are described in the Atlas of Zeolite StructureTypes by W. M. Meier and D. H. Olson (published by Butterworths onbehalf of the Structure Commission of the International ZeoliteAssociation). Zeolite catalysts having crystal structures that areessentially the same as the crystal structures of the above-mentionedzeolite catalysts, but differ slightly therefrom in chemicalcomposition, can also be used. Examples of such zeolites include zeolitecatalysts obtained by removal of a number of aluminum ions from, or bysteaming of, the above-mentioned zeolite catalysts, or zeolite catalystsobtained by addition of different elements, for example, by impregnationor cation exchange or by incorporation during the zeolite synthesis (forexample boron, iron and gallium).

[0026] Zeolite oligomerization catalysts can be made by any suitablemethod. One conventional technique includes heating a reaction mixturecontaining a source of silicon oxide, a source of aluminum oxide and, ifappropriate, an organic promoter, for example, a nitrogen orphosphorus-containing organic base, together optionally with an alkalimetal base, and separating the porous aluminosilicate crystals (zeoliteprecursor crystals) formed. The precursor crystals are then calcined inair or oxygen at a temperature exceeding 500° C.; for example, at atemperature of 550° C. for about 10 to about 20 hours. In oneembodiment, the calcined material is exchanged with ammonium ions (NH₄+)and subjected to conditions under which the ammonium ions decompose,with the formation of ammonia and a proton, thus producing an acidicform of the zeolite. Alternatively, the acidic form can be obtained byacid exchange with hydrochloric acid. If desired, however, the calcinedmaterial can be used as a catalyst without first being exchanged withammonium ions, since the material then already possesses acidic sites.The activity of the material is then significantly lower than that of amaterial that has been exchanged with ammonium ions and then subjectedto conditions under which the ammonium ions decompose.

[0027] Ammonium exchanged and calcined monodimensional 10-ringszeolites, examples of which include ZSM-22 and ZSM-23, can be treated toselectivate their surface, thereby forming a selectivated catlayst. Thisselectivation can be achieved in numerous ways. As one example, thezeolites can be titrated with an organic nitrogen base, such ascollidine. See, for example, U.S. Pat. No. 5,026,933 to Blain et al.,the description of which is incorporated herein by reference. Anotherexample is by depositing a crystalline Si:Al layer on a core of zeolite,such as ZSM-22 or ZSM-23, where this layer has a higher Si:Al ratio thanthe untreated zeolite. See, for example, U.S. Pat. No. 6,013,851, thedescription of which is incorporated herein by reference.

[0028] The olefin feed stream that is to be oligomerized in thisinvention includes at least one C₂ to C₁₂ olefin. Preferably the olefinfeed stream comprises at least one C₂ to C₈ olefin, more preferably atleast one C₃ to C₆ olefin.

[0029] In one embodiment, the olefin feed steam that is oligomerizedcontains at least 50 wt % olefin. Preferably, the olefin feed streamcomprises at least about 55 wt % olefin, more preferably at least about60 wt % olefin.

[0030] In another embodiment, the olefin feed stream comprises less thanabout 50 wt % paraffin. More preferably, the olefin feed streamcomprises less than about 45 wt % paraffin, more preferably less thanabout 40 wt % paraffin.

[0031] The inventors have found that the acid based oligomerizationcatalysts used in this invention are adversely sensitive to even lowlevels of oxygenated hydrocarbons in the olefin feed. This sensitivityis demonstrated by a significant reduction in catalyst life in thepresence of certain levels of oxygenated hydrocarbons. The exhibitedsensitivity is quite unexpected, since it is known that addition of lowlevels of water (a non-hydrocarbon oxygenate) to the olefin feed canactually increase the catalytic life of the zeolite oligomerizationcatalysts. See, for example, U.S. Pat. No. 5,672,800 which showshydration can improve zeolite oligomerization catalyst life.

[0032] Examples of oxygenated hydrocarbon to which the acid basedoligomerization catalysts are adversely sensitive are alcohols,aldehydes, ketones, ethers and carboxylic acids. Oxygenated hydrocarbonswhich particularly affect the acid based oligomerization catalystsinclude methanol, butyl alcohol, dimethyl ether, methyl ethyl ketone,acetic acid, and propionic acid.

[0033] In one embodiment of the invention, the olefin feed stream thatis to be oligomerized comprises less than 1,000 ppm by weight of theoxygenated hydrocarbon. Preferably, the olefin feed stream that is to beoligomerized comprises less than about 900 ppm by weight of theoxygenated hydrocarbon, more preferably less than about 800 ppm byweight of the oxygenated hydrocarbon.

[0034] It is not necessary that the olefin feed stream be completelydevoid of oxygenated hydrocarbon. An amount of oxygenated hydrocarboncan be present, so long as it does not significantly adversely affectcatalytic life of the oligomerization catalyst. In this regard, anolefin feed stream containing greater than about 500 ppm by weightoxygenated hydrocarbon is tolerable. Preferably, the level is somewhatlower. A lower limit of greater than about 100 ppm by weight is moredesirable, with a lower limit of at least about 50 ppm by weight beingeven more desirable, and a lower limit of at least about 5 ppm by weightbeing particularly preferred. Lower limits of oxygenated hydrocarbon arenot warranted as the oligomerization catalyst can satisfactorilytolerate very low levels, and it is technically difficult to removeoxygenated hydrocarbons to lower levels; particularly when the olefinfeed stream is derived from processes such as oxygenate to olefinsprocesses, which will generally contain substantial quantities ofoxygenated hydrocarbons in the olefin product.

[0035] In another embodiment of the invention, the olefin feed streamthat is oligomerized in this invention is predominantly derived from anoxygenate to olefins unit; meaning that at least 50 wt % of the olefinfeed, preferably at least 60 wt %, and more preferably at least 70 wt %of the olefin feed, is derived from an oxygenate to olefins unit. Such afeed stream should be low in sulfur, nitrogen and chlorine, to theextent that essentially no pretreatment will be required for removal ofsuch components. In addition, such a feed stream should have arelatively low concentration of paraffins, compared to such sources asolefins from cracked hydrocarbon source. However, such a feed streamwill generally contain oxygenated hydrocarbon at a level which wouldlikely adversely impact catalytic life of the zeolite oligomerizationcatalyst. Therefore, removal of such components are likely required. Thebenefit in using an oxygenate to olefins stream is that lower levels ofinert components, such as propane and butane, are present.

[0036] Desirably, the olefin feed stream is obtained by contactingoxygenate with a molecular sieve catalyst. The oxygenate comprises atleast one organic compound which contains at least one oxygen atom, suchas aliphatic alcohols, ethers, carbonyl compounds (aldehydes, ketones,carboxylic acids, carbonates, esters and the like). When the oxygenateis an alcohol, the alcohol includes an aliphatic moiety having from 1 to10 carbon atoms, more preferably from 1 to 4 carbon atoms.Representative alcohols include but are not necessarily limited to lowerstraight and branched chain aliphatic alcohols and their unsaturatedcounterparts. Examples of suitable oxygenate compounds include, but arenot limited to: methanol; ethanol; n-propanol; isopropanol; C₄-C₂₀alcohols; methyl ethyl ether; dimethyl ether; diethyl ether;di-isopropyl ether; formaldehyde; dimethyl carbonate; dimethyl ketone;acetic acid; and mixtures thereof. Preferred oxygenate compounds aremethanol, dimethyl ether, or a mixture thereof.

[0037] A molecular sieve catalyst is used in this invention in theoxygenate to olefin reaction. Such a molecular sieve is defined as anymolecular sieve capable of converting an oxygenate to an olefincompound. Examples of these molecular sieves include zeolites as well asnon-zeolites, and are of the large, medium or small pore type. Smallpore molecular sieves are preferred in one embodiment of this invention,however. As defined herein, small pore molecular sieves have a pore sizeof less than about 5.0 Angstroms. Generally, suitable catalysts have apore size ranging from about 3.5 to about 5.0 angstroms, preferably fromabout 4.0 to about 5.0 Angstroms, and most preferably from about 4.3 toabout 5.0 Angstroms.

[0038] Zeolites which are particularly useful as an oxygenate to olefinscatalyst include the ZSM type zeolites. Examples of the ZSM typezeolites include ZSM-4, ZSM-5, ZSM-11, ZSM-12, ZSM-13, ZSM-22, ZSM-23,and ZSM-57.

[0039] Another type of olefin forming catalyst useful in this inventionis one containing a silicoaluminophosphate (SAPO) molecular sieve.Silicoaluminophosphate molecular sieves are generally classified asbeing microporous materials having 8, 10, or 12 membered ringstructures. These ring structures can have an average pore size rangingfrom about 3.5 to about 15 angstroms. Preferred are the small pore SAPOmolecular sieves having an average pore size of less than about 5angstroms, preferably an average pore size ranging from about 3.5 toabout 5 angstroms, more preferably from about 3.5 to about 4.2angstroms. These pore sizes are typical of molecular sieves having 8membered rings.

[0040] According to one embodiment, substituted SAPOs can also be usedin oxygenate to olefin reaction processes. These compounds are generallyknown as MeAPSOs or metal-containing silicoaluminophosphates. The metalcan be alkali metal ions (Group IA), alkaline earth metal ions (GroupIIA), rare earth ions (Group IIIB, including the lanthanoid elements:lanthanum, cerium, praseodymium, neodymium, samarium, europium,gadolinium, terbium, dysprosium, holmium, erbium, thulium, ytterbium andlutetium; and scandium or yttrium) and the additional transition cationsof Groups IVB, VB, VIB, VIIB, VIIIB, and IB.

[0041] Preferably, the Me represents atoms such as Zn, Mg, Mn, Co, Ni,Ga, Fe, Ti, Zr, Ge, Sn, and Cr. These atoms can be inserted into thetetrahedral framework through a [MeO₂] tetrahedral unit. The [MeO₂]tetrahedral unit carries a net electric charge depending on the valencestate of the metal substituent. When the metal component has a valencestate of +2, +3, +4, +5, or +6, the net electric charge is between −2and +2. Incorporation of the metal component is typically accomplishedadding the metal component during synthesis of the molecular sieve.However, post-synthesis ion exchange can also be used. In post synthesisexchange, the metal component will introduce cations into ion-exchangepositions at an open surface of the molecular sieve, not into theframework itself.

[0042] Suitable silicoaluminophosphate molecular sieves include SAPO-5,SAPO-8, SAPO-11, SAPO-16, SAPO-17, SAPO-18, SAPO-20, SAPO-31, SAPO-34,SAPO-35, SAPO-36, SAPO-37, SAPO-40, SAPO-41, SAPO-42, SAPO-44, SAPO-47,SAPO-56, the metal containing forms thereof, and mixtures thereof.Preferred are SAPO-18, SAPO-34, SAPO-35, SAPO-44, and SAPO-47,particularly SAPO-18 and SAPO-34, including the metal containing formsthereof, and mixtures thereof. As used herein, the term mixture issynonymous with combination and is considered a composition of matterhaving two or more components in varying proportions, regardless oftheir physical state.

[0043] An aluminophosphate (ALPO) molecular sieve can also be includedin the oxygenate to olefins catalyst composition. Aluminophosphatemolecular sieves are crystalline microporous oxides which can have anAIPO₄ framework. They can have additional elements within the framework,typically have uniform pore dimensions ranging from about 3 angstroms toabout 10 angstroms, and are capable of making size selective separationsof molecular species. More than two dozen structure types have beenreported, including zeolite topological analogues. A more detaileddescription of the background and synthesis of aluminophosphates isfound in U.S. Pat. No. 4,310,440, which is incorporated herein byreference in its entirety. Preferred ALPO structures are ALPO-5,ALPO-11, ALPO-18, ALPO-31, ALPO-34, ALPO-36, ALPO-37, and ALPO-46. TheALPOs can also include a metal substituent in its framework. Preferably,the metal is selected from the group consisting of magnesium, manganese,zinc, cobalt, and mixtures thereof. These materials preferably exhibitadsorption, ionexchange and/or catalytic properties similar toaluminosilicate, aluminophosphate and silica aluminophosphate molecularsieve compositions. Members of this class and their preparation aredescribed in U.S. Pat. No. 4,567,029, incorporated herein by referencein its entirety.

[0044] The metal containing ALPOs have a three-dimensional microporouscrystal framework structure of MO₂, AlO₂ and PO₂ tetrahedral units.These as manufactured structures (which contain template prior tocalcination) can be represented by empirical chemical composition, on ananhydrous basis, as:

mR: (M_(x)Al_(y)P_(z))O₂

[0045] wherein “R” represents at least one organic templating agentpresent in the intracrystalline pore system; “m” represents the moles of“R” present per mole of (M_(x)Al_(y)P_(z))O₂ and has a value of fromzero to 0.3, the maximum value in each case depending upon the moleculardimensions of the templating agent and the available void volume of thepore system of the particular metal aluminophosphate involved, “x”, “y”,and “z” represent the mole fractions of the metal “M”, (i.e. magnesium,manganese, zinc and cobalt), aluminum and phosphorus, respectively,present as tetrahedral oxides.

[0046] The metal containing ALPOs are sometimes referred to by theacronym as MeAPO. Also in those cases where the metal “Me” in thecomposition is magnesium, the acronym MAPO is applied to thecomposition. Similarly ZAPO, MnAPO and CoAPO are applied to thecompositions which contain zinc, manganese and cobalt respectively. Toidentify the various structural species which make up each of thesubgeneric classes MAPO, ZAPO, CoAPO and MnAPO, each species is assigneda number and is identified, for example, as ZAPO-5, MAPO-1 1, CoAPO-34and so forth.

[0047] The silicoaluminophosphate molecular sieve is typically admixed(i.e., blended) with other materials. When blended, the resultingcomposition is typically referred to as a SAPO catalyst, with thecatalyst comprising the SAPO molecular sieve.

[0048] Materials which can be blended with the molecular sieve can bevarious inert or catalytically active materials, or various bindermaterials. These materials include compositions such as kaolin and otherclays, various forms of rare earth metals, metal oxides, othernon-zeolite catalyst components, zeolite catalyst components, alumina oralumina sol, titania, zirconia, magnesia, thoria, beryllia, quartz,silica or silica or silica sol, and mixtures thereof. These componentsare also effective in reducing, inter alia, overall catalyst cost,acting as a thermal sink to assist in heat shielding the catalyst duringregeneration, densifying the catalyst and increasing catalyst strength.It is particularly desirable that the inert materials that are used inthe catalyst to act as a thermal sink have a heat capacity of from about0.05 to about 1 cal/g-° C., more preferably from about 0.1 to about 0.8cal/g-° C., most preferably from about 0.1 to about 0.5 cal/g-° C.

[0049] Additional molecular sieve materials can be included as a part ofthe SAPO catalyst composition or they can be used as separate molecularsieve catalysts in admixture with the SAPO catalyst if desired.Structural types of small pore molecular sieves that are suitable foruse in this invention include AEI, AFT, APC, ATN, ATT, ATV, AWW, BIK,CAS, CHA, CHI, DAC, DDR, EDI, ERI, GOO, KFI, LEV, LOV, LTA, MON, PAU,PHI, RHO, ROG, THO, and substituted forms thereof. Structural types ofmedium pore molecular sieves that are suitable for use in this inventioninclude MFI, MEL, MTW, EUO, MTT, HEU, FER, AFO, AEL, TON, andsubstituted forms thereof. These small and medium pore molecular sievesare described in greater detail in the Atlas of Zeolite StructuralTypes, W. M. Meier and D. H. Olsen, Butterworth Heineman, 3rd ed., 1997,the detailed description of which is explicitly incorporated herein byreference. Preferred molecular sieves which can be combined with asilicoaluminophosphate catalyst include ZSM-5, ZSM-34, erionite, andchabazite.

[0050] The catalyst composition, according to an embodiment, preferablycomprises from about 1% to about 99%, more preferably from about 5% toabout 90%, and most preferably from about 10% to about 80%, by weight ofmolecular sieve. It is also preferred that the catalyst composition havea particle size of from about 20 microns to about 3,000 microns, morepreferably from about 30 microns to about 200 microns, most preferablyfrom about 50 microns to about 150 microns.

[0051] The catalyst can be subjected to a variety of treatments toachieve the desired physical and chemical characteristics. Suchtreatments include, but are not necessarily limited to hydrothermaltreatment, calcination, acid treatment, base treatment, milling, ballmilling, grinding, spray drying, and combinations thereof.

[0052] A preferred catalyst of this invention is a catalyst whichcontains a combination of SAPO-34, and SAPO-18 or ALPO-18 molecularsieve. In a particularly preferred embodiment, the molecular sieve is acrystalline intergrowth of SAPO-34, and SAPO-18 or ALPO-18.

[0053] To convert oxygenate to olefin for use as olefin feed,conventional reactor systems can be used, including fixed bed, fluid bedor moving bed systems. Preferred reactors of one embodiment areco-current riser reactors and short contact time, countercurrentfree-fall reactors. Desirably, the reactor is one in which an oxygenatefeedstock can be contacted with a molecular sieve catalyst at a weighthourly space velocity (WHSV) of at least about 1 hr⁻¹, preferably in therange of from about 1 hr⁻¹ to 1000 hr⁻¹, more preferably in the range offrom about 20 hr⁻¹ to about 1000 hr⁻¹, and most preferably in the rangeof from about 20 hr⁻¹ to about 500 hr⁻¹. WHSV is defined herein as theweight of oxygenate, and hydrocarbon which may optionally be in thefeed, per hour per weight of the molecular sieve content of thecatalyst. Because the catalyst or the feedstock may contain othermaterials which act as inerts or diluents, the WHSV is calculated on theweight basis of the oxygenate feed, and any hydrocarbon which may bepresent, and the molecular sieve contained in the catalyst.

[0054] Preferably, the oxygenate feed is contacted with the catalystwhen the oxygenate is in a vapor phase. Alternately, the process may becarried out in a liquid or a mixed vapor/liquid phase. When the processis carried out in a liquid phase or a mixed vapor/liquid phase,different conversions and selectivities of feed-to-product may resultdepending upon the catalyst and reaction conditions.

[0055] The oxygenate to olefins process can generally be carried out ata wide range of temperatures. An effective operating temperature rangecan be from about 200° C. to about 700° C., preferably from about 300°C. to about 600° C., more preferably from about 350° C. to about 550° C.At the lower end of the temperature range, the formation of the desiredolefin products may become markedly slow. At the upper end of thetemperature range, the process may not form an optimum amount ofproduct.

[0056] Olefins obtained by cracking hydrocarbon streams can also be usedto form the olefin feed stream of this invention. It is preferable,however, that such olefins be combined with the olefin product of theoxygenate conversion reaction. This is because the olefins obtained by acracking process are generally high in non-reactive hydrocarboncomponents such as alkanes, are high in branchiness, and are high inother undesirable by-products such as sulfur, which can cause conversionproblems in the higher olefin reaction process. Therefore, additionalpurification of such a stream would be needed.

[0057] The olefin feed of this invention has a substantially reducedsulfur, nitrogen and/or chlorine content. According to one embodiment,the olefin feed also contains isoolefin at a concentration that does notsubstantially adversely affect the linear quality of dimerized oroligomerized product. Such product contains enough n-olefin andmono-branched mono-olefin to provide derivative products, particularlyesters, that are highly desirable for industrial end uses. Esterderivatives from the dimer and oligomer products of this invention willbe particularly suitable for use as plasticizers.

[0058] The sulfur content of the olefin feed of this invention should besufficiently low such that the activity of the catalyst used to form theolefin dimer or oligomer is not substantially inhibited. Preferably, thesulfur content in the olefin feed is not greater than about 1 ppm; morepreferably, not greater than about 0.5 ppm; and most preferably, notgreater than about 0.3 ppm by weight, calculated on an atomic basis.

[0059] The nitrogen content of the olefin feed of this invention shouldalso be sufficiently low such that the catalytic activity of thecatalyst used to form the olefin dimer or oligomer is not substantiallyinhibited. Preferably, the nitrogen content in the olefin feed is notgreater than about 1 ppm; more preferably, not greater than about 0.5ppm; and most preferably, not greater than about 0.3 ppm by weight,calculated on an atomic basis.

[0060] The chlorine content of the olefin feed of this invention shouldalso be sufficiently low such that the catalytic activity of thecatalyst used to form the olefin dimer or oligomer is not substantiallyinhibited. Preferably, the chlorine content in the olefin feed is notgreater than about 0.5 ppm; more preferably, not greater than about 0.4ppm; and most preferably, not greater than about 0.3 ppm by weight,calculated on an atomic basis.

[0061] It is also desirable, according to one embodiment, that theolefin feed stream of this invention be high in linear mono-olefincontent so as to maintain a sufficiently high conversion to higherolefin product having few branches. Preferably, the olefin feed streamcomprises at least about 50 wt % linear monoolefin, more preferably atleast about 60 wt % linear mono-olefin; and most preferably at leastabout 70 wt % linear mono-olefin. Preferably, the linear monoolefin is aC₂ to C₆ linear mono-olefin and has a C₆ and higher hydrocarbon contentof not greater than about 20 wt %; more preferably, not greater thanabout 15 wt %; and most preferably, not greater than about 10 wt %.

[0062] The olefin feed streams of this invention are contacted with theacid based oligomerization catalyst in order to form desirable dimerand/or oligomer products. As used herein, dimerization andoligomerization processes are considered interchangeable terms. Theprocesses are also known as higher olefins processes. Dimerizationprocesses, oligomerization processes and higher olefins formingprocesses are all phrases that define the dimerization and/oroligomerization of light olefins, particularly C₃-C₆ olefins, to form adimer or oligomer product, the product also referred to as a higherolefin.

[0063] Conventional processes for removing oxygenated hydrocarbons fromolefin streams can be used to produce the olefin feed stream used inthis invention. Such methods include water and alcohol washing, causticscrubbing, distillation, extractive distillation and fixed bedadsorption. Other desirable methods, such as those found in Kirk-OthmerEncyclopedia of Chemical Technology, 4th edition, Volume 9, John Wiley &Sons, 1996, pg. 894-899, the description of which is incorporated hereinby reference, can also be used. In addition, purification systems suchas that found in Kirk-Othmer Encyclopedia of Chemical Technology, 4thedition, Volume 20, John Wiley & Sons, 1996, pg. 249-271, thedescription of which is also incorporated herein by reference, can beused.

[0064] In one embodiment of the invention, olefin feed streams that areoligomerized according to this invention can be derived from a mainolefin source and treated to reduce oxygenated hydrocarbon content. Thetreated olefin stream can then be further separated to produce an olefinfeed of a particularly preferred range, e.g., C₂ to C₆ olefins.

[0065] In another embodiment of the invention, the olefin feed streamthat is to be oligomerized is separated according to a particularlypreferred range, and the separated olefin feed is treated to reduceoxygenated hydrocarbon. The order of separation and/or treatment toreduce oxygenated hydrocarbon content is not critical to the invention.

[0066] In another embodiment of the invention, acid basedoligomerization catalyst life, particularly the life of zeoliteoligomerization catalysts are increased by hydrating the olefin feedstream prior to contacting the stream with the catalyst. This means thatan amount of water effective in substantially increasing catalyst lifeis added. Preferably, water is added to the olefin feed stream such thatthe stream comprises from about 0.05 weight percent to about 2 weightpercent water. More preferably, water is added to the olefin feed streamsuch that the stream comprises from about 0.1 weight percent to about 1weight percent water. The desired proportion of water may beincorporated by saturating the feed at an appropriate temperature, e.g.,from about 25° C. to about 60° C., or by injecting water through a pump.

[0067] The oligomerization reaction process can take place at anytemperature effective in oligomerizing olefin feed to oligomer product.In general, the reaction takes place at a temperature of from about 170°C. to about 300° C., preferably from about 170° C. to about 260° C., andmost preferably from about 180° C. to about 260° C.

[0068] Operating pressures are not critical to the oligomerizationreaction. In general the reaction process is carried out at a pressureof from about 5 MPa to about 10 MPa, preferably from about 6 MPa toabout 8 MPa.

[0069] Flow of olefin feed through the reactor should be sufficient tocarry out a reasonably high conversion, but not so low that there aresignificant amounts of undesirable side reactions. In general, thereaction is carried out at a weight hourly space velocity (WHSV) of fromabout 0.1 hr⁻¹ to about 20 hr⁻¹, preferably from about 1 hr⁻¹ to about10 hr⁻¹, and most preferably from about 1.5 hr⁻¹ to about 7.5 hr⁻¹.

[0070] Following the oligomerization reaction, the higher olefin productis optionally recovered, and further converted to desirable derivativeproducts. These derivative products can be paraffin mixtures, obtainedby conventional hydrogenation processes and optional blending and/oradditional distillation. The paraffin mixtures can be used ashydrocarbon fluids and/or solvents in many applications, includingpaints and coatings, process fluids, metal cleaning, dry cleaning,cosmetics, pharmaceuticals, agrochemicals, degreasing, aerosolpropellants, adhesives, cleaners, inks, and other industrial andhousehold products.

[0071] Other higher olefins derivatives include thiols (often calledmercaptans) or sulfides, which are produced by reacting with a sulfurcompound. These are valuable starting materials for agriculturalchemicals, pharmaceuticals, cosmetic ingredients, antioxidants,fragrance components and polysulfides. They are also used aspolymerization regulators in rubber and plastics manufacture.

[0072] Examples of other derivatives include alkylated aromatics, usingconventional alkylation processes. The alkylated aromatics can befurther processed to their lubricant components or surfactantderivatives, or used as a hydrocarbon fluid as is.

[0073] A particularly desirable conversion process for higher olefins iscarbonylation in general or hydroformylation in particular. Theseprocesses lead to various derivatives, including esters, aldehydes, andalcohols. An overview of catalysts and reaction conditions ofhydroformylation processes is given for example by Beller et al. inJournal of Molecular Catalysis, A104 (1995), pages 17-85, the details ofwhich are incorporated herein by reference. See also UllmannsEncyclopedia of Industrial Chemistry, Vol. A5 (1986), pages 217 to 233;which is also incorporated herein by reference. Further description isfound in J.Falbe, Carbon Monoxide in Organic Synthesis, 1967; andJ.Falbe, New Synthesis with Carbon Monoxide, 1980.

[0074] Hydroformylation involves the contacting of the higher olefinproduct, carbon monoxide and hydrogen with the hydroformylation catalystor its precursor. Hydroformylation catalysts are organometalliccomplexes of the metals of Group VIII of the periodic system, optionallyused in combination as bior tri-metallic systems, and optionally withsalts of other metals as promoters, for example tin chloride. Thecatalytic organometallic complexes are combinations of catalytic metalswith various ligands. Preferred metals are cobalt, rhodium andpalladium.

[0075] The organometallic catalyst can be introduced as the activeorganometallic complex, or the complexes can be made in situ fromcatalyst precursors and ligands introduced into a reaction zone.Suitable catalyst precursors include, for example, the respective metalhydrides, halides, nitrates, sulfates, oxides, sulfides and salts oforganic acids. Such acids include formates, acetates, or heavieralkylcarboxylic acids such as oleates or naphthenates. Other organicacids which can be used include alkylsulfonic or arylsulfonic acids.

[0076] Particularly desirable complexes for the hydroformylation of thehigher olefins of this invention are the carbonyl compounds of themetals mentioned, as well as those containing amines, triorganicderivatives of phosphorous, arsenic or antimony, the respective oxidesof these derivatives, optionally functionalized to make them soluble inphases that under certain conditions can be separated from the organicreactor liquid.

[0077] Hydroformylation is desirably carried out at a temperatureranging from about 40° C. to about 220° C. Preferred is a temperatureranging from about 80° C. to about 200° C.; particularly about 90° C. toabout 180° C.

[0078] Hydroformylation can be carried out at conventionalhydroformylation pressure ranges. In general, hydroformylation isacceptable at a pressure range of from about 1 to about 400 bar gauge.Medium and high pressure ranges are preferred ranges. In general, mediumand high pressure ranges are considered to be in the range of about 40to about 400 bar gauge, more specifically in the range of about 50 toabout 320 bar gauge. Within these general pressure ranges CO-ligandedcatalyst processes are particularly useful.

[0079] A high pressure range is generally considered in the range ofabout 175 to about 400 bar gauge, more desirably about 190 to about 310bar gauge. CO-liganged rhodium and cobalt catalyst processes areparticularly useful in these high pressure ranges.

[0080] A medium pressure range is generally considered to be in therange of about 40 to about 175 bar gauge, more desirably about 50 toabout 150 bar gauge, and with certain catalysts it is desirable to bewithin a range of from about 60 to about 90 bar gauge. As an example, atriphenylphosphineoxide (TPPO)-liganded rhodium catalyst is particularlydesirable in the range of from about 50 to about 150 bar guage. Asanother example, a trialkylphosphine-liganded cobalt catalyst isparticularly desirable in the range of from about 60 to about 90 bargauge.

[0081] Hydroformylation can also be carried out in low pressure ranges.In general, the low pressure range will be in the range of from about 5to about 50 bar gauge, although a pressure range of from about 10 toabout 30 bar gauge is particularly useful. An example of ahydroformylation catalyst which is particularly useful in the lowpressure range is phosphine-liganded rhodium, more particularlytriphenylphosphine-liganded rhodium.

[0082] Other hydroformylation catalysts can be used within the pressureranges described. Such catalysts are described in Kirk-Othmer, 4^(th)Edition, Volume 17, “Oxo Process,” pages 902-919 and Ullman'sEncyclopedia of Industrial Chemistry, 5^(th) Edition, Volume A18, “OxoSynthesis,” pages 321-327, the detailed descriptions of each beingincorporated herein by reference.

[0083] It is desirable in some instances that hydroformylation becarried out at a carbon monoxide partial pressure not greater than about50% of the total pressure. The proportions of carbon monoxide andhydrogen used in the hydroformylation or oxo reactor at the foregoingpressures are desirably maintained as follows: CO from about 1 to about50 mol %, preferably from about 1 to about 35 mol %; and H₂ from about 1to about 98 mol %, preferably from about 10 to about 90 mol %.

[0084] The hydroformylation reaction is conducted in a batch modeaccording to one embodiment. Alternatively, the hydroformylationreaction can occur on a continuous basis. In a continuous mode, aresidence time of up to 4 hours is useful. If a plurality of reactors isemployed, a residence time as short as 1 minute is advantageous.Alternatively a residence time is in the range of from about ½ to about2 hours is useful.

[0085] Since the hydroformylation process of the invention takes placein the liquid phase and the reactants are gaseous compounds, a highcontact surface area between the gas and liquid phases is desirable toavoid mass transfer limitations. A high contact surface area between thecatalyst solution and the gas phase is obtainable in a variety of ways.For example and without limitation, contact surface area between thegaseous reactants and the liquid phase is obtained by stirring in abatch autoclave operation. In a continuous operation, the olefin feedstream of one embodiment is contacted with catalyst solution in, forexample, a continuous-flow stirred autoclave where the feed isintroduced and dispersed at the bottom of the vessel, preferably througha perforated inlet. Good contact between the catalyst and the gas feedis obtainable by dispersing a solution of the catalyst on a high surfacearea support. Such a technique is commonly referred to as supportedliquid phase catalysis. The catalyst is provided as part of a permeablegel.

[0086] The hydroformylation reaction is performed in a single reactoraccording to one embodiment. Examples of suitable reactors are found inU.S. Pat. Nos. 4,287,369 and 4,287,370 (Davy/UCC); U.S. Pat. No.4,322,564 (Mitsubishi); U.S. Pat. No. 4,479,012 and EP-A-114,611 (bothBASF); EP-A-103,810 and EP-A-144,745 (both Hoechst/Ruhrchemie); and U.S.Pat. No. 5,763,678 (Exxon). Two or more reactor vessels or reactorschemes configured in parallel are used in another embodiment. Inaddition, a plug flow reactor design, optionally with partial liquidproduct backmixing, provides an efficient use of reactor volume.

[0087] It is preferred, according to one embodiment, that thehydroformylation reaction be carried out in more than one reaction zoneor vessel in series. Suitable reactor configurations are disclosed, forexample, by Fowler et al in British Patent Specification No. 1,387,657,by Bunning et al in U.S. Pat. No. 4,593,127, by Miyazawa et al in U.S.Pat. No. 5,105,018, by Unruh et al in U.S. Pat. No. 5,367,106. and byBeckers et al. in U.S. Pat. No. 5,763,678. Examples of individualhydroformylation reactors can of the standard types described by Denbighand Turner in Chemical Reactor Theory ISBN 0 521 07971 3, by Perry et alin Chemical Engineers' Handbook ISBN 0-07-085547-1 or any more recenteditions, e.g., a continuous stirred tank or a plug flow reactor withadequate contact of the gas and the liquid flowing through the reactor.Advantageously these plug flow reactor designs or configurations includeways of partial backmixing of the reactor product liquid, as explained,for example, by Elliehausen et al in EP-A-3,985 and in DE 3,220,858.100871 Hydroformylated products have utility as intermediates in themanufacture of numerous commercially important chemicals, with theinvention further providing processes in which hydroformylation isfollowed by reactions producing such chemicals. The reaction productswill typically be a mixture of oxygenated compounds, since the higherolefin components used to make the products will generally include amixture of components. The higher olefin components are generally amixture of components, because the olefin feed stream that is used tomake the oligomeric olefin product will generally include a mixture ofolefins. However, the resulting hydroformylation product stream willgenerally be higher in linearity as a result of the high degree oflinearity of the oligomeric olefin and olefin compositions used upstreamof the hydroformylation reaction process.

[0088] Either in their pure form, or as part of the mixture in thehydroformylation product, aldehydes which are produced are optionallyaldolized, a term which includes the dehydration of the aldol condensateto form an unsaturated aldehyde. This aldolization can be performed withthe other aldehydes present in the stream, or with aldehydes that wereprepared separately and are added to the original aldehyde orhydroformylation product stream.

[0089] Aldol product is optionally hydrogenated to the correspondingalcohol mixture. If desired, the unsaturated aldehyde mixture fromaldolization can be selectively hydrogenated to form the saturatedaldehyde mixture. Any of the saturated aldehyde mixtures, either as madeby hydroformylation or by selective hydrogenation of an aldol product,can have special value when they are oxidized to their correspondingcarboxylic acids, or condensed with formaldehyde to polyols, or withammonia to imines which can be hydrogenated to amines. The acids andpolyols are valuable intermediates for esters, polyol esters, metalsalts, amides, and again for imines and amines.

[0090] Under circumstances where the olefin feed is ultimately derivedfrom a low-value feedstock like natural gas, i.e., in cases wheremethane from natural gas is converted to methanol and the methanol toolefin, the products or product mixtures may have value as liquidtransportable fuels, optionally after dehydration to the olefin, and ifdesired hydrogenation to a paraffin or paraffinic mixture. Particularlyvaluable compositions produce according to this invention are isononylalcohol mixtures, made by hydroformylation and hydrogenation of octenemixtures. The invention also provides a valuable process for themanufacture of isooctanoic acid, wherein the aldehyde fromhydroformylation of a heptene mixture is separated from thehydroformylation product and subsequently oxidized.

[0091] In another embodiment of the invention, the hydroformylationproducts of this invention are optionally hydrogenated to saturatedalcohols. Formation of a saturated alcohol may be carried out, ifdesired, in two stages through a saturated aldehyde, or in a singlestage to the saturated alcohol, in which case it is desirable to form asaturated aldehyde as an intermediate. The alcohols are then optionallyesterified, etherified, or formed into acetals or carbonates, which canbe used as plasticizers, surfactants or synthetic lubricants. The estersand ethers of the invention, or produced by the process of theinvention, are suitable for use as solvents, paint coalescers,plasticizers, adhesives, surfactants, viscosity index improvers,synthetic lubricants, flame retardants, lubricant components, anti-wearagents, hydraulic fluids, cetane improvers, drilling fluids,thermoplastic and textile processing aids, polymer, especially vinylchloride polymer, stabilizers, polymerizable monomers and fragrances.

[0092] Esterification is accomplished by reacting the alcohols of thisinvention with acids or anhydrides. The reaction process desirably takesadvantage of conventional processes. In these conventional processes, itis desirable to react the alcohols and acids at elevated temperaturesand pressures, and to drive the reaction toward completion by removingwater that is produced as a by-product.

[0093] Catalysts may be employed in the esterification reaction.Suitable catalysts include, for example, titanium containing catalysts,e.g., a tetraalkyl titanate, in particular tetra-iso-propyl ortetraoctyl ortho titanate, or sulphonic acid containing catalysts, e.g.,p-toluene sulphonic acid or methylsulphonic acid. Also sulphuric acidcatalyst may be used. Alternatively, the esterification reaction may bepreformed without the addition of a dedicated catalyst.

[0094] Catalyst present in the esterification reaction product may beremoved by alkali treatment and water washing. Advantageously, thealcohol is used in slight, e.g., from 10 to 25%, molar excess relativeto the number of acid groups in the acid.

[0095] The acid of the ester may be inorganic or organic; if the latter,a carboxylic acid is preferred. Aromatic acids or their anhydrides arepreferred for plasticizer manufacture, although aliphatic acids are alsoemployed. Additional examples of acids include, acetic, propionic,valeric, isovaleric, n-heptanoic, noctanoic, n-decanoic, neodecanoic,lauric, stearic, iso-stearic, oleic, erucic, succinic, phthalic(1,2-benzenedicarboxylic), isophthalic, terephthalic, adipic, fumaric,azelaic, 2-methylpentanoic, 2,4-dimethylheptanoic,2,4,6-trimethylnonanoic, sebacic, benzoic, trimellitic, pyromellitic,acrylic, methacrylic, tall oil, monobasic or dibasic cyclohexanoic,naphthenic and naphthalene-type acids, carbonic, nitric, sulphuric,phosphoric and phosphorous and their thioanalogous, acids and C₆ to C₁₃oxo and neo acids. The esters of the Cg and especially the C₁₂ alcoholswith oxo and neo acids are especially useful as drilling fluids andpower transmission fluids. Phosphate esters are particularly desirableas flame retardants; while phosphite esters provide vinyl chloridepolymer stabilizers.

[0096] Esters with monobasic and dibasic acids are preferred forlubricants and lubricant components. Advantageously the resulting esterscontain from 15 to 40 carbon atoms. Adipates, azelates, and phthalatesare especially preferred for lubricant manufacture. Esters withunsaturated carboxylic acids, e.g., with acrylic and methacrylic acid,provide polymerizable monomers, suitable as sole or comonomer inthermoplastics manufacture, or in polymers used in or as adhesives, VIimprovers, and coating resins.

[0097] The esters of the invention may be used as a plasticizer fornumerous polymers. Examples include cellulose acetate; homo- andcopolymers of aromatic vinyl compounds e.g., styrene, or of vinyl esterswith carboxylic acids e.g., ethylene/vinyl acetate copolymers;halogen-containing polymers, especially vinyl chloride homo- andcopolymers, more especially those copolymers with vinyl esters ofcarboxylic acids, esters of unsaturated carboxylic acids e.g.,methacrylates, and/or olefins; nitrile rubbers; and post-chlorinatedvinyl chloride polymers. Poly(vinyl chloride) is of particular interest.

[0098] The proportion of plasticizer ester to polymer may vary withinwide limits. A desirable range is from about 10 to about 200 parts byweight per 100 parts of polymer, preferably from about 20 to about 100parts per 100 parts of polymer.

[0099] The esters of the invention may be used alone as plasticizer, orin admixture with one another, or in admixture with other plasticizers,for example, dibutyl, dipentyl, dihexyl, diheptyl, dioctyl, dinonyl,didecyl, diundecyl, didodecyl, ditridecyl phthalates, trimellitates oradipates, or butyl benzyl phthalate, or mixtures thereof. They may also,or instead, be used with a secondary plasticizer, e.g., a chlorinatedparaffin, Texanol isobutyrate, or a processing oil. If used inadmixture, it is the total proportion of plasticizer that isadvantageously within the ranges given above.

[0100] The plasticized polymeric compositions of the invention may bemade up in numerous forms and have various end-uses. For example, theymay be in the form of a dryblend, a paste, or a plastisol, depending onthe grade of the resin employed. They may be used, for example, ascoatings, in dipping, spraying, injection or rotational molding,extrusion, or as self-supporting films and sheets, and may readily befoamed. End uses include flooring materials, wall coverings, moldedproducts, upholstery materials, leather substitutes, electricalinsulation, especially wire and cable, coated fabrics, toys, andautomobile parts.

[0101] The invention also provides a composition comprising an ester ofthe invention and a refrigerant, especially a fluorocarbon refrigerant,and more especially HFC 32 (difluoromethane) or HFC 134a(1,1,1,2-tetrafluoroethane). More especially, the invention providessuch a composition also comprising at least one of a hydrolyticstability enhancer, e.g., a hindered phenol or an aromatic amine, anantioxidant, corrosion inhibitor, and a metal deactivator.

[0102] The following examples represent various embodiments of theinvention, within the overall scope of the invention as described in theclaims.

EXAMPLE 1

[0103] An olefin feed comprising 64 wt % butenes and 35 wt % butane, thebalance comprising propane and propylene was hydrated by passing theolefin feed at a temperature of about 39° C. through a thermostatedwater saturator prior to introducing the feed into an oligomeriztionreactor containing ZSM-22. The hydrated feed, which contained 600 ppm byweight water, was then contacted with the ZSM-22 in the reactor todetermine catalyst life at 92% conversion. The results are shown in theFIGURE.

EXAMPLE 2

[0104] Acetic acid was added to a portion of the hydrated olefin feed inExample 1 to obtain an acetic acid concentration of 300 ppm by weight.The olefin feed was then contacted with ZSM-22 catalyst in anoligomerization reactor to determine catalyst life at 92% conversion.The results are shown in the FIGURE.

EXAMPLE 3

[0105] Butanol and methyl ethyl ketone (MEK) was added to an olefin feedcomprising 64 wt % butenes and 35 wt % butane, the balance comprisingpropane and propylene to obtain an olefin feed stream containing 2 wt %butanol and 2 wt % MEK. The resulting olefin feed stream was thencontacted with ZSM-22 in an oligomerization reactor to determinecatalyst life at 92% conversion. The results are shown in the FIGURE.

[0106] The data of Examples 1-3, as shown in the FIGURE, demonstratethat oxygenated hydrocarbon can adversely affect catalyst life ofzeolite oligomerization catalyst.

[0107] Having now fully described this invention, it will be appreciatedby those skilled in the art that the invention can be performed within awide range of parameters within what is claimed, without departing fromthe spirit and scope of the invention.

What is claimed is:
 1. A method of oligomerizing olefin, comprising:removing oxygenated hydrocarbon from an olefin stream containing atleast one C₂ to C₁₂ olefin to obtain an olefin feed stream comprisingless than 1,000 ppm by weight oxygenated hydrocarbon; and contacting theolefin feed with an acid based oligomerization catalyst to oligomerizethe olefin in the olefin feed.
 2. The method of claim 1, wherein theacid based oligomerization catalyst is a solid phosphoric acid catalyst.3. The method of claim 1, wherein the acid based oligomerizationcatalyst is a zeolite oligomerization catalyst.
 4. The method of claim3, wherein the zeolite oligomerization catalyst is selected from thegroup consisting of TON, MTT, MFI, MEL, MTW, EUO, ZSM-57, ferrierites,offretites, ZSM-4, ZSM-18, ZSM-23, Zeolite Beta, faujasites, zeolite L,mordenites, erionites and chabazites.
 5. The method of claim 4, whereinthe zeolite oligomerization catalyst is ZSM-22, ZSM-23 or ZSM-57.
 6. Themethod of claim 5, wherein the zeolite oligomerization catalyst isZSM-22 or ZSM-23.
 7. The method in claim 6, wherein the zeoliteoligomerization catalyst is a selectivated catalyst.
 8. The method ofclaim 1, wherein the olefin feed contains less than 50 wt % alkane. 9.The method of claim 8, wherein the olefin feed contains at least 50 wt %olefin.
 10. The method of claim 1, wherein the olefin stream is obtainedby contacting oxygenate with a molecular sieve catalyst.
 11. The methodof claim 10, wherein the oxygenate is methanol or dimethyl ether. 12.The method of claim 1, wherein the olefin feed is hydrated prior tocontacting with the acid based oligomerization catalyst.
 13. The methodof claim 12, wherein the hydrated olefin feed has a water content of0.05 to 2 weight percent.
 14. The method of claim 1, wherein the olefinfeed stream comprises greater than 5 ppm by weight oxygenatedhydrocarbon.
 15. A method of making an olefin oligomer from anoxygenate, comprising: contacting the oxygenate with a molecular sievecatalyst to form an olefin stream containing at least one C₂ to C₁₂olefin; removing oxygenated hydrocarbon from the olefin stream to obtainan olefin feed stream comprising less than 1,000 ppm by weightoxygenated hydrocarbon; and contacting the olefin feed stream with anacid based oligomerization catalyst to form an olefin oligomer.
 16. Themethod of claim 15, wherein the acid based oligomerization catalyst is asolid phosphoric acid catalyst.
 17. The method of claim 15, wherein theacid based oligomerization catalyst is a zeolite oligomerizationcatalyst.
 18. The method of claim 17, wherein the zeoliteoligomerization catalyst is selected from the group consisting of TON,MTT, MFI, MEL, MTW, EUO, ZSM-57, ferrierites, offretites, ZSM-4, ZSM-18,ZSM-23, Zeolite Beta, faujasites, zeolite L, mordenites, erionites andchabazites.
 19. The method of claim 18, wherein the zeoliteoligomerization catalyst is ZSM-22, ZSM-23 or ZSM-57.
 20. The method ofclaim 19, wherein the zeolite oligomerization catalyst is ZSM-22 orZSM-23.
 21. The method of claim 20, wherein the zeolite oligomerizationcatalyst is a selectivated catalyst.
 22. The method of claim 15, whereinthe olefin feed contains less than 50 wt % alkane.
 23. The method ofclaim 22, wherein the olefin feed contains at least 50 wt % olefin. 24.The method of claim 15, wherein the oxygenate is methanol or dimethylether.
 25. The method of claim 15, wherein the olefin feed is hydratedprior to contacting with the oligomerization catalyst.
 26. The method ofclaim 25, wherein the hydrated olefin feed has a water content of 0.05to 2 weight percent.
 27. The method of claim 15, wherein the olefin feedstream comprises greater than 5 ppm by weight oxygenated hydrocarbon.28. A method of making an olefin oligomer from an oxygenate, comprising:contacting the oxygenate with a molecular sieve catalyst to form anolefin stream containing at least one C₂ to C₁₂ olefin; recovering a C₃to C₆ olefin stream from the olefin stream, removing oxygenatedhydrocarbon from the olefin stream to obtain an olefin feed streamcomprising less than 1,000 ppm by weight oxygenated hydrocarbon; andcontacting the olefin feed stream with an acid based oligomerizationcatalyst to form an olefin oligomer.
 29. The method of claim 28, whereinthe acid based oligomerization catalyst is a solid phosphoric acidcatalyst.
 30. The method of claim 28, wherein the acid basedoligomerization catalyst is a zeolite oligomerization catalyst.
 31. Themethod of claim 30, wherein the zeolite oligomerization catalyst isselected from the group consisting of TON, MTT, MFI, MEL, MTW, EUO,ZSM-57, ferrierites, offretites, ZSM-4, ZSM-18, ZSM-23, Zeolite Beta,faujasites, zeolite L, mordenites, erionites and chabazites.
 32. Themethod of claim 31, wherein the zeolite oligomerization catalyst isZSM-22, ZSM-23 or ZSM-57.
 33. The method of claim 32, wherein thezeolite oligomerization catalyst is ZSM-22 or ZSM-23.
 34. The method ofclaim 33, wherein the zeolite oligomerization catalyst is selectivatedcat.
 35. The method of claim 27, wherein the olefin feed contains lessthan 50 wt % alkane.
 36. The method of claim 35, wherein the olefin feedcontains at least 50 wt % olefin.
 37. The method of claim 28, whereinthe oxygenate is dimethyl ether.
 38. The method of claim 28, wherein theolefin feed is hydrated prior to contacting with the oligomerizationcatalyst.
 39. The method of claim 38, wherein the hydrated olefin feedhas a water content of 0.05 to 2 weight percent.
 40. The method of claim28, wherein the olefin feed stream comprises greater than 5 ppm byweight oxygenated hydrocarbon.
 41. A method of making an olefin oligomerfrom an oxygenate, comprising: contacting the oxygenate with a molecularsieve catalyst to form an olefin stream containing at least one C₂ toC₁₂ olefin; removing oxygenated hydrocarbon from the olefin stream;recovering a C₃ to C₆ olefin stream from the olefin stream, followingremoval of the oxygenated hydrocarbon, to obtain an olefin feed stream,wherein the olefin feed stream contains less than 1,000 ppm by weightoxygenated hydrocarbon; and contacting the olefin feed with an acidbased oligomerization catalyst to form an olefin oligomer.
 42. Themethod of claim 41, wherein the acid based oligomerization catalyst is asolid phosphoric acid catalyst.
 43. The method of claim 41, wherein theacid based oligomerization catalyst is a zeolite oligomerizationcatalyst.
 44. The method of claim 43, wherein the zeoliteoligomerization catalyst is selected from the group consisting of TON,MTT, MFI, MEL, MTW, EUO, ZSM-57, ferrierites, offretites, ZSM-4, ZSM-18,ZSM-23, Zeolite Beta, faujasites, zeolite L, mordenites, erionites andchabazites.
 45. The method of claim 44, wherein the zeoliteoligomerization catalyst is ZSM-22, ZSM-23 or ZSM-57.
 46. The method ofclaim 45, wherein the zeolite oligomerization catalyst is ZSM-22 orZSM-23.
 47. The method of claim 46, wherein the zeolite oligomerizationcatalyst is a selectivated catalyst.
 48. The method of claim 41, whereinthe olefin feed contains less than 50 wt % alkane.
 49. The method ofclaim 48, wherein the olefin feed contains at least 50 wt % olefin. 50.The method of claim 41, wherein the oxygenate is methanol or dimethylether.
 51. The method of claim 41, wherein the olefin feed is hydratedprior to contacting with the oligomerization catalyst.
 52. The method ofclaim 51, wherein the hydrated olefin feed has a water content of 0.05to 2 weight percent.
 53. The method of claim 41, wherein the olefin feedstream comprises greater than 5 ppm by weight oxygenated hydrocarbon.54. A method of oligomerizing olefin, comprising: providing an olefinfeed stream comprising at least one C₂ to C₁₂ olefin and oxygenatedhydrocarbon, wherein the oxygenated hydrocarbon is provided in theolefin stream at a concentration of greater than 5 ppm by weight andless than 1,000 ppm by weight; and contacting the olefin feed with anacid based oligomerization catalyst to oligomerize the olefin in theolefin feed.
 55. The method of claim 54, wherein the acid basedoligomerization catalyst is solid phosphoric acid catalyst.
 56. Themethod of claim 54, wherein the acid based oligomerization catalyst is azeolite oligomerization catalyst.
 57. The method of claim 56, whereinthe zeolite oligomerization catalyst is selected from the groupconsisting of TON, MTT, MFI, MEL, MTW, EUO, ZSM-57, ferrierites,offretites, ZSM-4, ZSM-18, ZSM-23, Zeolite Beta, faujasites, zeolite L,mordenites, erionites and chabazites.
 58. The method of claim 57,wherein the zeolite oligomerization catalyst is ZSM-22, ZSM-23 orZSM-57.
 59. The method of claim 58, wherein the zeolite oligomerizationcatalyst is ZSM-22 or ZSM-23.
 60. The method of claim 59, wherein thezeolite oligomerization catalyst is a selectivated catalyst.
 61. Themethod of claim 54, wherein the olefin feed contains less than 50 wt %alkane.
 62. The method of claim 61, wherein the olefin feed contains atleast 50 wt % olefin.
 63. The method of claim 54, wherein the olefinstream is obtained by contacting oxygenate with a molecular sievecatalyst.
 64. The method of claim 63, wherein the oxygenate is methanolor dimethyl ether.
 65. The method of claim 54, wherein the olefin feedis hydrated prior to contacting with the oligomerization catalyst. 66.The method of claim 65, wherein the hydrated olefin feed has a watercontent of 0.05 to 2 weight percent.